Dry goods container

ABSTRACT

A dry goods container has a container body, a top portion constructed of injection molded plastic, and a cap portion. The container body includes a container base and a container sidewall, the container base having a base perimeter, and the container sidewall extending upwardly from the base perimeter to form a top perimeter that defines a top opening of the container body. The container body is constructed of paperboard and sealed with a barrier layer. The top portion is adapted to engage the top perimeter and close the top opening of the container body. The top portion has a generally planar box top surface and an indented portion, the indented portion having a pouring aperture surrounded by a pour spout. The cap portion is shaped to removably engage the pour spout to seal the pouring aperture.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

[0002] Not Applicable

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] This invention relates generally to containers, and moreparticularly to a container adapted to contain dry goods such as cereal.

[0005] 2. Description of Related Art

[0006] The prior art teaches the construction of paperboard containers,known as “gable” type containers, for use in storing and dispensingdrinks such as milk and fruit juice. The most recent gable typecontainers have included a fitment type pour spout formed of plastic andaffixed to one of the upper sloped sides of the gable container. Fordispensing with this type of container, the user unscrews a screw capand pours a desired quantity of liquid and then recluses the containerby threading the cap back on the spout. In the typical construction, asshown in Gordon, U.S. Pat. No. 4,964,562, a paperboard blank is firstcovered on either side with a plastic layer, and die cut into aplurality of panels that can then be folded to form the gable container.

[0007] The prior art also teaches the construction of paperboard cerealboxes, for use in storing and dispensing dry goods such as cereal. Atypical cereal box is merely a paperboard box into which is placed aplastic bag full of cereal. The user partially rips open the plastic bagto dispense the cereal; and the user folds the top portion of theplastic bag to reseal the bag and protect the cereal. The primaryproblem with this construction is that it is not convenient, especiallyfor children, to tear open the plastic bag containing the cereal.Furthermore, the rudimentary method of folding the plastic bag isinefficient in protecting the cereal, so the cereal tends to becomestale after a period of time.

[0008] Finally, the prior art teaches various plastic containers,commonly known as TUPPERWARE®, for storage of leftover foods. Theseplastic containers are typically washed and reused; however, they arenot suitable for product packaging due to the cost of construction.

[0009] The prior art does not teach a container adapted to store drygoods such as cereal that is so inexpensive to manufacture that it canbe used as disposable product packaging, and yet is easy to open,dispense cereal, and be readily and effectively resealed. The presentinvention fulfills these needs and provides further related advantagesas described in the following summary.

SUMMARY OF THE INVENTION

[0010] The present invention teaches certain benefits in constructionand use which give rise to the objectives described below.

[0011] The present invention provides a dry goods container having acontainer body, a top portion constructed of injection molded plastic,and a cap portion. The container body includes a container base and acontainer sidewall, the container base having a base perimeter, and thecontainer sidewall extending upwardly from the base perimeter to form atop perimeter that defines a top opening of the container body. Thecontainer body is constructed of paperboard and sealed with a barrierlayer. The top portion is adapted to engage the top perimeter and closethe top opening of the container body. The top portion has a generallyplanar box top surface and an indented portion, the indented portionhaving a pouring aperture surrounded by a pour spout. The cap portion isshaped to removably engage the pour spout to seal the pouring aperture.

[0012] A primary objective of the present invention is to provide a drygoods container having advantages not taught by the prior art.

[0013] Another objective is dry goods container that is constructedprimarily of paperboard, and therefore inexpensive enough to be used asdisposable product packaging, but includes a top portion that isinjection molded to include a pour spout and a cap portion, therebyenabling the dry goods container to be easily opened and resealed.

[0014] A further objective is to provide a dry goods container that hasa top portion and a cap portion that cooperate to provide a planarsurface that enables a plurality of the dry goods containers to beeasily stacked and securely stored and shipped.

[0015] Other features and advantages of the present invention willbecome apparent from the following more detailed description, taken inconjunction with the accompanying drawings, which illustrate, by way ofexample, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWING

[0016] The accompanying drawings illustrate the present invention. Insuch drawings:

[0017]FIG. 1 is a perspective, exploded view of a first embodiment ofthe present invention;

[0018]FIG. 2 is a perspective, partially exploded view of a secondembodiment of the present invention;

[0019]FIG. 3 is a perspective, partially exploded view of a thirdembodiment of the present invention;

[0020]FIG. 4 is a perspective view thereof; and

[0021]FIG. 5 is a top plan view of a paperboard blank that has been diecut into a plurality of panels that can be folded to form a containerbody.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The above described drawing figures illustrate the invention, adry goods container 10 for storing dry goods such as cereal and thelike. The dry goods container 10 is constructed primarily of paperboard,but includes a pour spout 56 that is constructed of molded plastic thatfacilitates dispensing the dry goods from the dry goods container 10.

[0023] As shown in FIG. 1, the dry goods container 10 includes acontainer body 20 that is constructed of a paperboard layer 22 and abarrier layer 24. The container body 20 includes a container base 26 anda container sidewall 36. The container base 26 is shaped to support thedry goods container 10 upon a surface. The container base 26 isgenerally planar, although a creative designer can create a more unusualshape that still functions to support the dry goods container 10 in themanner desired. The container base 26 has a base perimeter 28 from whichthe container sidewall 36 extends upwardly to form the remainder of thecontainer body 20. The container base 26 and the container sidewall 36together provide the container body 20 of the dry goods container 10 andfunction to contain the dry goods. The container body 20 is preferablysimilar to a standard cereal box in size, shape, and generalconstruction.

[0024] The barrier layer 24 is preferably formed with a wax coating thatis deposited onto an inside surface of the paperboard layer 22. The waxcoating 24 functions to seal the container body 20 to prevent the drygoods from becoming dry and stale. In an alternative embodiment, thebarrier layer 24 is provided by at least one plastic layer that isbonded to the paperboard layer 22. Further details of this form ofconstruction are well known in the art, and described in Gordon, U.S.Pat. No. 4,964,562, Craig, U.S. Pat. No. 3,432,069, and Moody et al.,U.S. Pat. No. 5,601,669, all of which are hereby incorporated byreference in full.

[0025] As shown in FIG. 1, the container base 26 is preferably generallyrectangular in shape such that the base perimeter 28 includes a frontedge 30, a back edge 32, and a pair of opposing side edges 34. In thisembodiment, the container sidewall 36 includes a front sidewall 38, anopposing back sidewall 40, a pair of opposing side sidewalls 42. Thefront sidewall 38 extends upwardly from the front edge 30, the backsidewall 40 extends upwardly from the back edge 32, and each of the pairof opposing side sidewalls extends 42 upwardly from one of the pair ofopposing side edges 34, the front sidewall 38 being joined to one edgeof each of the pair of opposing side sidewalls 42, the back sidewall 40being joined to the other edge of each of the pair of opposing sidesidewalls 42, thereby forming the container body 20.

[0026] Of course, alternative shapes can be equally effective. Onexample of an alternative shape, not shown, includes a round or ovalbase having a single upwardly extending sidewall that is bent to attachto the perimeter of the container base 26, thereby forming a cylindricalcontainer body 20. Other examples include a base shaped to form variouspolygons, or even more unusual curved shapes.

[0027] As shown in FIGS. 1-4, the dry goods container 10 furtherincludes a means for closing the top opening 76. The means for closingincludes a generally planar box top surface 50 and an indented portion52, the indented portion 52 having a pouring aperture 54 surrounded by apour spout 56. The means for closing is critical to the inventionbecause it integrates the pour spout 56, which is constructed ofplastic, with the container body 20, which is constructed of paperboard.The means for closing can be provided in several embodiments.

[0028] In a first embodiment, as shown in FIG. 1, the means for closingis a pour spout 56 having a spout base 60 with an annular flange 62. Thepour spout 56 has a diameter of at least 1.5 inches, and most preferablyhas a diameter of approximately 2-2.5 inches, or larger, to accommodatethe easy pouring of the dry goods from the dry goods container 10. Inthis embodiment, the generally planar box top surface 50 and theindented portion 52 are constructed of the paperboard layer 22 and thebarrier layer 24, and are integral with the container body 20. Thoseskilled in the art can devise many methods of folding andadhesive-bonding a paperboard blank to form the container body 20, aprocess described in greater detail below. Once the container body 20has been formed, the annular flange 62 of the pour spout 56 is bonded tothe indented portion 52 around the pouring aperture 54, either with anadhesive layer 64 or ultrasonic welding, as well known in the art and asdescribed in greater detail in Gordon, U.S. Pat. No. 4,964,562, Craig,U.S. Pat. No. 3,432,069, and Moody et al., U.S. Pat. No. 5,601,669, allof which are hereby incorporated by reference in full.

[0029] In a second embodiment, as shown in FIG. 2, the means for formingthe top portion includes an integrally molded top portion 70 thatprovides the generally planar box top surface 50 and an indented portion52 as an integral molded plastic piece. The indented portion 52 has thepouring aperture 54, the pour spout 56, and a downwardly extendingflange 72 that are also integrally formed. In this embodiment, thefront, back, and side sidewalls 38, 40, and 42 preferably together forma top perimeter 74 that defines a top opening 76 of the container body20, and the downwardly extending flange 72 is adapted to engage the topperimeter 74. The downwardly extending flange 72 is then bonded to thetop perimeter 74 in the same manner as described above.

[0030] In a third embodiment, as shown in FIGS. 3-4, the means forclosing includes a top sidewall 80 that is integral with the containerbody 20 and shaped to cover a portion of the top opening 76. In thisembodiment, the means for closing further includes an alternative topportion 82 that is similar to the top portion 70 described above, onlyhaving a partial downwardly extending flange 84, shorter than thedownwardly extending flange 72, and further including a rearwardlyextending flange 86. The partial downwardly extending flange 84 and therearwardly extending flange 86 together are adapted to engage the topperimeter 74 and a top portion leading edge 88, respectively, to closethe top opening 76. The partial downwardly extending flange 84 is bondedto the top perimeter 74, and the rearwardly extending flange 86 isbonded to the top portion leading edge 88, in the same manner asdescribed above.

[0031] As shown in FIGS. 1-5, the dry goods container 10 also includes acap portion 90 shaped to removably engage the pour spout 56 to seal thepouring aperture 54. The cap portion 90 is preferably shaped to eitherthreadedly engage the pour spout 56, or frictionally engage the pourspout 56, and the cap portion 90 preferably includes tamper evidentfeatures (not shown) well known in the art. The cap portion 90 providesa generally planar cap top surface 92 that is generally coplanar withthe generally planar box top surface 50. It is important that thegenerally planar cap top surface 92 and the generally planar box topsurface 50 are generally coplanar because this enables the dry goodscontainer 10 to be stacked, stored and shipped more efficiently. Thegenerally planar box top surface 50 and the generally planar cap topsurface 92 preferably lie on a plane that is generally parallel to thecontainer base 26.

[0032] For purposes of this application the geometric terms relating tosurfaces, planes, and relative orientations are meant to provide only ageneral description of the functional shapes and relative orientationsof the various surfaces, not a precise geometric description. Forpurposes of this application, a surface or plane is formed by thefunctional interaction of at least three surface points, and the actualshape can include curves and other ornamental features as long as theornamentation does not detract from the functional features of thevarious elements. Describing the planes as parallel or coplanar is onceagain only meant in general terms regarding the functionality of theelement, and precise geometric measurements are not meant to be implied.

[0033] The invention includes a method for packaging dry goods using theabove-described product. First, a paperboard blank 94 is coated with abarrier layer 24, preferably a wax layer or alternatively a plasticlayer. The paperboard blank 94 is then die cut into a plurality ofintegral panels 96, shown in FIG. 5. Developing a suitable die can beaccomplished by one skilled in the art. The plurality of integral panels96 are then folded and bonded to each other to form the container body20 described above, also according to techniques well known in the art.

[0034] The top portion 70 and the cap portion 90 are then formed througha process of plastic injection molding, and provided with the containerbody 20 for filling. The container body 20 is filled with the dry goodsand the top portion 70 is positioned to cover the top opening 76 suchthat the downwardly extending flange 72 engages the top perimeter 74.Finally, the top portion 70 is bonded to the top perimeter 74. In thepreferred embodiment, the downwardly extending flange 72 of the topportion 70 is inserted into the top opening 76, thereby engaging the topperimeter 74, and the downwardly extending flange 72 is bonded to thetop perimeter 74, either with an adhesive, ultrasonic welding, or anequivalent attachment process.

[0035] While the invention has been described with reference to at leastone preferred embodiment, it is to be clearly understood by thoseskilled in the art that the invention is not limited thereto. Rather,the scope of the invention is to be interpreted only in conjunction withthe appended claims.

What is claimed is:
 1. A dry goods container comprising: a containerbody having a container base and a container sidewall, the containerbase having a base perimeter, and the container sidewall extendingupwardly from the base perimeter to form a top perimeter that defines atop opening of the container body, the container body being constructedof a paperboard layer that is sealed with a barrier layer; a top portionadapted to engage the top perimeter and close the top opening of thecontainer body, the top portion having a generally planar box topsurface and an indented portion, the indented portion having a pouringaperture surrounded by a pour spout; and a cap portion shaped toremovably engage the pour spout to seal the pouring aperture.
 2. The drygoods container of claim 1 wherein the top portion includes a generallyplanar box top surface and the cap portion includes a generally planarcap top surface, the generally planar box top surface and the generallyplanar cap top surface being coplanar and generally parallel to thecontainer base.
 3. The dry goods container of claim 1 wherein thebarrier layer is provided by a wax coating on an interior surface of thecontainer body.
 4. The dry goods container of claim 1 wherein the topportion is formed of injection molded plastic and includes a downwardlyextending flange that is shaped to engage with the top perimeter of thecontainer body such that the top portion is positioned to close the topopening of the container body.
 5. The dry goods container of claim 1wherein the pour spout has a diameter of at least 1.5 inches.
 6. The drygoods container of claim 1 wherein the pour spout has a diameter of atleast 2 inches.
 7. The dry goods container of claim 1 wherein the pourspout has a diameter of at least 2.5 inches.
 8. A dry goods containercomprising: a container body having a container base and a containersidewall, the container base having a base perimeter, and the containersidewall extending upwardly from the base perimeter to form a topperimeter that defines a top opening of the container body, thecontainer body being constructed of a paperboard layer that is sealedwith a barrier layer; a means for closing the top opening, the means forclosing providing a generally planar box top surface and an indentedportion, the indented portion having a pouring aperture surrounded by apour spout; and a cap portion shaped to removably engage the pour spoutto seal the pouring aperture, the cap portion providing a generallyplanar cap top surface, the generally planar box top surface and thegenerally planar cap top surface being generally coplanar.
 9. The drygoods container of claim 8 wherein the generally planar box top surfaceand the generally planar cap top surface together lie on a plane that isgenerally parallel to the container base.
 10. The dry goods container ofclaim 8 wherein the means for closing includes a pour spout having aspout base with an annular flange, wherein the generally planar box topsurface and the indented portion of the means for closing are integralwith the container body; and wherein the annular flange of the pourspout is bonded to the indented portion around the pouring aperture. 11.The dry goods container of claim 8 wherein the base is generallyrectangular in shape and the base perimeter includes a front edge, aback edge, and a pair of opposing side edges, wherein the sidewallincludes a front sidewall, an opposing back sidewall, a pair of opposingside sidewalls, and wherein the front sidewall extends upwardly from thefront edge, the back sidewall extends upwardly from the back, and eachof the pair of opposing side sidewalls extends upwardly from one of thepair of opposing side edges, the front sidewall being joined to one edgeof each of the pair of opposing side sidewalls, the back sidewall beingjoined to the other edge of each of the pair of opposing side sidewalls.12. The dry goods container of claim 11 wherein the front, back, andside sidewalls together form a top perimeter that defines a top openingof the container body; and wherein the means for closing is a topportion having a downwardly extending flange that is adapted to engagethe top perimeter, the downwardly extending flange being adapted to bebonded to the top perimeter.
 13. The dry goods container of claim 11wherein the front, back, and side sidewalls together form a topperimeter that defines a top opening of the container body; wherein themeans for closing includes a top sidewall integral with the containerbody and shaped to cover a portion of the top opening; and wherein themeans for closing further includes an alternative top portion having apartial downwardly extending flange and a rearwardly extending flangethat together are adapted to engage the top perimeter and a top portionleading edge to close the top opening, the partial downwardly extendingflange being bonded to the top perimeter, and the rearwardly extendingflange being bonded to the top portion leading edge.
 14. A method forpackaging dry goods, the method comprising the steps of: providing apaperboard blank that has been covered with or bonded to a barrier layerand die cut into a plurality of integral panels; folding the pluralityof integral panels, and bonding the plurality of integral panels to eachother, to form a container body having a container base and a containersidewall, the container base having a base perimeter, and the containersidewall extending upwardly from the base perimeter, the containersidewall extending upwardly from the base perimeter to form a topperimeter that defines a top opening of the container body; providing atop portion that has been formed through plastic injection molding, thetop portion having a pouring aperture surrounded by a pour spout, thetop portion further having a downwardly extending flange; and providinga cap portion that has been formed through plastic injection molding,the cap portion being shaped to removably engage the pour spout to sealthe pouring aperture.
 15. The method of claim 14 further comprising thesteps of: filling the container body with the dry goods; positioning thetop portion to cover the top opening such that the downwardly extendingflange engages the top perimeter; and bonding the downwardly extendingflange to the top perimeter.